U.S. patent application number 13/627398 was filed with the patent office on 2013-04-04 for anti-fatigue mat with removable resilient cushioning member.
This patent application is currently assigned to LET'S GEL INCORPORATED. The applicant listed for this patent is LET'S GEL INCORPORATED. Invention is credited to John P. Busch, Derric C. Hobbs, Robert L. McMahan, Scott D. Robertson, Ira L. Rush.
Application Number | 20130084413 13/627398 |
Document ID | / |
Family ID | 47992832 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130084413 |
Kind Code |
A1 |
McMahan; Robert L. ; et
al. |
April 4, 2013 |
ANTI-FATIGUE MAT WITH REMOVABLE RESILIENT CUSHIONING MEMBER
Abstract
An anti-fatigue mat provides a "dual mode" feature wherein the
anti-fatigue mat includes a resilient cushioning member that may be
removed to enable cleaning of the remainder of the mat and/or the
resilient cushioning member. The anti-fatigue mat includes a wear
element having a wear surface on which a user may stand. The
resilient cushioning member is situated adjacent the wear element
in a receiver that is attached to the wear element. The receiver
receives the resilient cushioning member via an aperture through
which the resilient cushioning member may be installed and removed.
The receiver may include multiple apertures to facilitate
installation and removal of the resilient cushioning member. The
anti-fatigue mat also provides a "dual friction" feature wherein
the interior surface of the wear element may exhibit high friction
with respect to the resilient cushioning member, and the receiver
exhibits sufficiently high friction to reduce slippage on a
floor.
Inventors: |
McMahan; Robert L.; (Cedar
Park, TX) ; Busch; John P.; (Austin, TX) ;
Rush; Ira L.; (Austin, TX) ; Robertson; Scott D.;
(Austin, TX) ; Hobbs; Derric C.; (Austin,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LET'S GEL INCORPORATED; |
Austin |
TX |
US |
|
|
Assignee: |
LET'S GEL INCORPORATED
Austin
TX
|
Family ID: |
47992832 |
Appl. No.: |
13/627398 |
Filed: |
September 26, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61645016 |
May 9, 2012 |
|
|
|
61543305 |
Oct 4, 2011 |
|
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Current U.S.
Class: |
428/33 ; 428/138;
428/68; 428/71 |
Current CPC
Class: |
A47G 27/0231 20130101;
B32B 5/18 20130101; Y10T 428/24331 20150115; Y10T 428/233 20150115;
B32B 3/14 20130101; B32B 5/24 20130101; B32B 3/26 20130101; B32B
3/04 20130101; C08J 5/18 20130101; Y10T 428/23 20150115; B32B 3/02
20130101; B32B 2266/0278 20130101; B32B 3/06 20130101 |
Class at
Publication: |
428/33 ; 428/68;
428/138; 428/71 |
International
Class: |
B32B 3/04 20060101
B32B003/04; B32B 3/26 20060101 B32B003/26; B32B 3/06 20060101
B32B003/06; B32B 3/02 20060101 B32B003/02; B32B 3/14 20060101
B32B003/14; B32B 3/24 20060101 B32B003/24 |
Claims
1. An anti-fatigue mat, comprising: a wear element including a wear
surface for supporting a user; a resilient cushioning member; and a
receiver, attached to the wear element, that receives the resilient
cushioning member therein, the receiver including an aperture
through which the resilient element may be installed and
removed.
2. The anti-fatigue mat of claim 1, wherein the anti-fatigue mat
operates in a first mode in which the resilient cushioning member
is situated in the receiver.
3. The anti-fatigue mat of claim 1, wherein the anti-fatigue mat
operates in a second mode in which a resilient cushioning member is
not situated in the receiver.
4. The anti-fatigue mat of claim 1, wherein the resilient
cushioning member is comprised of foam.
5. The anti-fatigue mat of claim 1, wherein the resilient
cushioning member is comprised of gel.
6. The anti-fatigue mat of claim 1, wherein the resilient
cushioning member is comprised of gel and foam.
7. The anti-fatigue mat of claim 1, wherein the wear element
comprises a textile.
8. The anti-fatigue mat of claim 1, wherein the receiver is
integral to the wear element.
9. The anti-fatigue mat of claim 1, wherein the receiver includes
first and second receiver sections with the aperture therebetween
through which the resilient cushioning member may pass.
10. The anti-fatigue mat of claim 9, wherein the first and second
receiver sections are non-overlapping at the aperture.
11. The anti-fatigue mat of claim 10, wherein the first and second
receiver sections are overlapped at the aperture.
12. An anti-fatigue mat, comprising: a wear element including a
wear surface for supporting a user; a resilient cushioning member;
and a receiver, attached to the wear element, that receives the
resilient cushioning member therein, the receiver including an
aperture through which the resilient element may be installed and
removed; wherein the wear element includes a first mat interior
surface opposed to the wear surface, the first mat interior surface
of the wear element exhibiting high friction that reduces movement
of the wear element relative to the resilient cushioning member
when the resilient cushioning member is inside the receiver.
13. The anti-fatigue mat of claim 11, wherein the receiver includes
an exterior surface and a second mat interior surface opposed to
the exterior surface, wherein the second mat interior surface
contacts the first mat interior surface when the resilient
cushioning member is removed from the mat, the high friction
exhibited by the first mat interior surface of the wear element
relative to the second mat interior surface of the receiver
reducing movement of the wear element relative to the receiver.
14. The anti-fatigue mat of claim 13, wherein the second mat
interior surface exhibits low friction.
15. The anti-fatigue mat of claim 14, wherein the exterior surface
of the receiver comprises an anti-slip surface.
16. The anti-fatigue mat of claim 12, wherein the first mat
interior surface exhibits a friction sufficiently high to reduce
bunching of the wear element when the wear element supports a
user.
17. The anti-fatigue mat of claim 12, wherein the receiver includes
an exterior surface and a second mat interior surface opposed to
the exterior surface, the second mat interior surface exhibiting
low friction relative to the resilient cushioning member to
facilitate installation of the resilient cushioning member in the
receiver or removal of the resilient cushioning member from the
receiver.
18. The anti-fatigue mat of claim 12, wherein the resilient
cushioning member includes rounded corners.
19. The anti-fatigue mat of claim 12, wherein the resilient
cushioning member exhibits a rectangular geometry including first,
second, third and fourth sides that include first, second, third
and fourth cushion ramps, respectively.
20. The anti-fatigue mat of claim 19, wherein upon installation of
the resilient cushioning member in the receiver, the wear element
conforms to the geometry of the resilient cushioning member, such
that the wear element exhibits first, second, third and fourth wear
element ramps above the first, second, third and fourth cushion
ramps, respectively.
21. The anti-fatigue mat of claim 12, wherein the receiver includes
first and second receiver sections with a first aperture between
the first and second receiver sections.
22. The anti-fatigue mat of claim 21, wherein the receiver includes
a third receiver section with a second aperture between the second
and third receiver sections.
23. The anti-fatigue mat of claim 22 wherein the first receiver
section includes an access opening between the first aperture and a
side of the first receiver section.
24. The anti-fatigue mat of claim 21, wherein the first and second
receiver sections overlap at the first aperture.
25. The anti-fatigue mat of claim 12, wherein the resilient
cushioning member include multiple layers exhibiting different
respective durometers.
26. An anti-fatigue mat, comprising: a wear element including a
wear surface for supporting a user; and a receiver, attached to the
wear element, configured to receive a resilient cushioning member
therein, the receiver including an aperture through which the
resilient element may be installed and removed.
27. The anti-fatigue mat of claim 26, wherein the receiver includes
an exterior surface that is an anti-slip surface that interfaces
with a floor.
28. The anti-fatigue mat of claim 26, wherein the wear element
includes a first mat interior surface opposed to the wear surface,
the first mat interior surface of the wear element exhibiting high
friction to reduce movement of the wear element relative to a
second mat interior surface of the receiver when the resilient
cushioning member is not in the receiver.
29. The anti-fatigue mat of claim 26, wherein the resilient
cushioning member is situated in the receiver, wherein the wear
element includes a first mat interior surface opposed to the wear
surface, the first mat interior surface of the wear element
exhibiting high friction, such that the anti-fatigue mat reduces
movement of the wear element relative to the resilient cushioning
member situated in the receiver.
30. An anti-fatigue mat, comprising: a wear element including a
wear surface for supporting a user; a resilient cushioning member;
and a receiver, attached to the wear element, that receives the
resilient cushioning member therein, the receiver including an
aperture through which the resilient element may be installed and
removed, wherein the resilient cushioning member includes first and
second resilient cushioning member sections, the first resilient
cushioning member section including a first connector that connects
with a second connector on the second resilient cushioning member
section to hold the first resilient cushioning member section to
the second resilient cushioning member section.
31. The anti-fatigue mat of claim 30, wherein the first and second
connectors are puzzle-piece connectors.
32. The anti-fatigue mat of claim 30, wherein the resilient
cushioning member includes rounded corners.
33. The anti-fatigue mat of claim 30, wherein the receiver includes
a first receiver section and a second receiver section with an
opening between the first and second receiver sections, the opening
exhibiting a geometry that provides access to the resilient
cushioning member for inserting the resilient cushioning member
into the receiver and removing the resilient cushioning member from
the receiver.
34. The anti-fatigue mat of claim 31, wherein the mat includes
first and second opposed edges, and third and forth opposed
edges.
35. The anti-fatigue mat of claim 34, wherein the mat includes a
serge that extends along the first, second, third and forth opposed
edges to connect the receiver to the wear element.
36. The anti-fatigue mat of claim 34, wherein the first and second
receiver sections overlap adjacent the first and second opposed
edges of the mat at the opening.
37. The anti-fatigue mat of claim 30, wherein the first resilient
cushioning member section and the second resilient cushioning
member section are comprised of die-cut foam.
38. The anti-fatigue mat of claim 30, wherein the first resilient
cushioning member section and the second resilient cushioning
member section are comprised of molded foam.
Description
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims priority to Provisional U.S.
Patent Application Ser. No. 61/543,305, filed Oct. 4, 2011,
inventors McMahan et al., entitled "ANTI-FATIGUE MAT WITH REMOVABLE
RESILIENT CUSHIONING MEMBER", which is incorporated herein by
reference in its entirety.
[0002] This patent application further claims priority to
Provisional U.S. Patent Application Ser. No. 61/645,016, filed May
9, 2012, inventors McMahan, et al., entitled "ANTI-FATIGUE MAT WITH
REMOVABLE RESILIENT CUSHIONING MEMBER", which is incorporated
herein by reference in its entirety.
BACKGROUND
[0003] Floor mats have been used for years to provide a cushion for
the person standing on the mat. However, fatigue can still result
when a person stands on a mat for an extended period of time.
Persons who work standing up most of the day, such as cashiers,
assembly line operators, people in home or commercial kitchens and
many others still experience fatigue after standing on a
conventional mat for long periods of time. Floor mats are often
provided with non-slip surfaces to lessen slippage and to thus
promote safety.
BRIEF SUMMARY
[0004] In one embodiment, an anti-fatigue mat includes a wear
element having a wear surface for supporting a user. The
anti-fatigue mat also includes a resilient cushioning member. The
anti-fatigue mat further includes a receiver, attached to the wear
element, that receives the resilient element therein, the receiver
including an aperture through which the resilient element may be
installed and removed. In one embodiment, the receiver and the
resilient cushioning member are parallel to the wear element.
[0005] In another embodiment, an anti-fatigue mat includes a wear
element having a wear surface for supporting a user. The
anti-fatigue mat also includes a resilient cushioning member. The
anti-fatigue mat further includes a receiver, attached to the wear
element, that receives the resilient cushioning member therein, the
receiver including an aperture through which the resilient element
may be installed and removed. In one embodiment, the wear element
includes a first mat interior surface opposed to the wear surface,
the first mat interior surface of the wear element exhibiting high
friction that reduces the movement of the wear element relative to
the resilient cushioning member when the resilient cushioning
member is inside the receiver.
[0006] In another embodiment, an anti-fatigue mat includes a wear
element including a wear surface for supporting a user. The
anti-fatigue mat also includes a resilient cushioning member. The
anti-fatigue mat further includes a receiver, attached to the wear
element, that receives the resilient cushioning member therein, the
receiver including an aperture through which the resilient element
may be installed and removed. In one embodiment, the resilient
cushioning member includes first and second resilient cushioning
member sections, the first resilient cushioning member section
including a first connector that connects with a second connector
on the second resilient cushioning member section to hold the first
resilient cushioning member section to the second resilient
cushioning member section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The appended drawings illustrate only exemplary embodiments
of the invention and therefore do not limit its scope because the
inventive concepts lend themselves to other equally effective
embodiments.
[0008] FIG. 1A is a perspective view of one embodiment of the
disclosed anti-fatigue mat that includes a receiver for a resilient
cushioning member, wherein the receiver includes non-overlapping
receiver sections.
[0009] FIG. 1B is perspective view of the wear surface of the
anti-fatigue mat of FIG. 1.
[0010] FIG. 1C is a perspective view of the resilient cushioning
member of the disclosed anti-fatigue mat.
[0011] FIG. 1D is a perspective view of a resilient cushioning
member employing gel pads bonded to a flexible sheet.
[0012] FIGS. 1E-1H are cross sections different resilient
cushioning members that may be used as the resilient cushioning
member of the disclosed anti-fatigue mat.
[0013] FIG. 1I is a perspective view of an embodiment of an
assembled anti-fatigue mat that includes a receiver.
[0014] FIG. 1J is a perspective view of another embodiment of an
assembled anti-fatigue mat that includes a receiver that extends
more closely to the edge of the mat than the mat of FIG. 1I.
[0015] FIG. 2A is a perspective view of another embodiment of the
disclosed anti-fatigue mat that includes a receiver for a resilient
cushioning member, wherein the receiver includes overlapping
receiver sections.
[0016] FIG. 2B is a perspective view of the anti-fatigue mat of
FIG. 2A showing the resilient cushioning member partially
installed.
[0017] FIG. 2C is a perspective view of the anti-fatigue mat of
FIG. 2A showing the resilient cushioning member fully
installed.
[0018] FIG. 2D is a cutaway perspective view the anti-fatigue mat
of FIG. 2A showing the resilient cushioning member fully installed
and with one receiver section raised by hand to make the resilient
cushioning member more visible.
[0019] FIG. 3A is a cross sectional view of the disclosed
anti-fatigue mat with a resilient cushioning member installed
therein.
[0020] FIG. 3B is a cross sectional view of the disclosed
anti-fatigue mat with a resilient cushioning member removed.
[0021] FIG. 3C is a perspective view of a resilient cushioning
member that the disclosed anti-fatigue mat may employ.
[0022] FIG. 3D is a plan view of the receiver side of one
embodiment of the disclosed anti-fatigue mat.
[0023] FIG. 3E is a perspective view of one embodiment of the
disclosed anti-fatigue mat after assembly.
[0024] FIG. 4A is a perspective view of the receiver side of one
embodiment of the disclosed anti-fatigue mat.
[0025] FIG. 4B is a plan view of the receiver side of the
embodiment of the disclosed anti-fatigue mat shown in FIG. 4A.
[0026] FIG. 5A is a perspective view of the receiver side of
another embodiment of the disclosed anti-fatigue mat.
[0027] FIG. 5B is a plan view of the receiver side of the
embodiment of the disclosed anti-fatigue mat shown in FIG. 5A.
[0028] FIG. 6A is a plan view of a die-cut resilient cushioning
member that includes multiple resilient cushioning member sections
connected by interlocking connectors in one embodiment of the
disclosed anti-fatigue mat.
[0029] FIG. 6B is a plan view of the disclosed anti-fatigue mat
after installation of the resilient cushioning member of FIG. 6A in
a receiver that includes openings to allow access to the
interlocking connectors of the resilient cushioning member.
[0030] FIG. 6C is a close-up view a portion of the anti-fatigue mat
of FIG. 6B that depicts overlap between adjacent receiver
sections.
[0031] FIG. 7A is a perspective view of a molded resilient
cushioning member that includes multiple resilient cushioning
member sections connected by interlocking connectors in one
embodiment of the disclosed anti-fatigue mat.
[0032] FIG. 7B is a close-up view of a portion of the resilient
cushioning member of FIG. 7A that depicts the interlocking
connectors between adjacent resilient cushioning member
sections.
DETAILED DESCRIPTION
[0033] Anti-fatigue cushioned mats may be fabricated as rubber or
vinyl mats that include a resilient layer or cushion. Advanced
anti-fatigue mats may include one or more resilient layers of gel
material. However, both of these types of anti-fatigue mats may not
be machine washable. The disclosed anti-fatigue mat includes a
resilient cushioning member that may be removed to enable the
remainder of the mat to be easily cleaned. In one embodiment,
removal of the resilient cushioning member also enables easy
cleaning of the resilient cushioning member itself. The
anti-fatigue mat includes a wear element having a wear surface on
which a user may stand. The wear element may support the user in
contact therewith. In one embodiment, the resilient cushioning
member is situated adjacent the wear element in a receiver that
holds the resilient cushioning member to the wear element. The
receiver receives the resilient cushioning member via an aperture
through which the resilient element may be installed and removed.
In one embodiment, the wear element may be visually attractive
textile.
[0034] FIG. 1A shows one embodiment of the disclosed anti-fatigue
mat 100. Anti-fatigue mat 100 includes opposed top and bottom
surfaces 100A and 1008, respectively, of which bottom surface 100B
is shown in this figure. Anti-fatigue mat 100 includes a wear
element 105 that may be fabricated of material generally acceptable
as material for rugs and carpeting, such as a flexible textile
material, for example. FIG. 1A depicts the bottom of the wear
element 105 in this particular view. Wear element 105 includes
opposed top and bottom surfaces, namely top surface 105A and bottom
surface 105B, of which bottom surface 105B is depicted in FIG. 1A.
Wear element 105 may be a textile that exhibits one or more of a
variety of colors, textures and yarns. Wear element 105 may be
customizable, durable, visually attractive and washable.
[0035] In this particular embodiment, a resilient cushioning member
receiver 110 is attached to the bottom surface 105B of the wear
element 105 to capture and hold a flexible resilient cushioning
member (not shown) inside resilient cushioning member receiver 110.
The receiver 110 may be sewn or otherwise attached to the wear
element 105. For example, receiver 110 may be attached to wear
element 105 via hook and loop fasteners. The receiver 110 may be
formed as an integral part of the wear element 105. The receiver
110 of FIG. 1A includes receiver section 110-1 and receiver section
110-2 with an aperture 115 situated between these two receiver
sections, as illustrated. In this particular embodiment, receiver
sections 110-1 and 110-2 are non-overlapping. In other embodiment,
receiver sections 110-1 and 110-2 may overlap at aperture 115. The
user or other entity may install the resilient cushioning member in
receiver 110 of anti-fatigue mat 100 by inserting the resilient
cushioning member through aperture 115. The resilient cushioning
member is also removable through aperture 115 when it is time to
wash, or otherwise clean, the wear element 105.
[0036] FIG. 1B shows the top 100A of the wear element 105 of the
anti-fatigue mat 100. The top 100A of the anti-fatigue mat 100
provides a wear surface 105A on which the user stands or which
otherwise contacts the user. The wear surface 105A of the mat 100
may be stylishly decorated with attractive patterns and/or colors
that would appeal to consumers, businesses and others.
[0037] FIG. 1C shows a representation of the resilient cushioning
member 120 that may be installed in the receiver 110 of the wear
element 105. The resilient cushioning member 120 is fabricated from
flexible resilient material such as foam, gel or other resilient
material that provides the user comfort when the user stands on the
anti-fatigue mat. In one embodiment, the resilient cushioning
member may be fabricated from both gel and foam. For example, in
such an embodiment, the resilient cushioning member may include a
layer of gel and a layer of foam sandwiched together. In another
embodiment, the resilient cushioning member may include a layer of
gel sandwiched between two foam layers. The top 120A and/or the
bottom 120B of the resilient cushioning member 120 may include
non-slip surfaces to arrest, minimize or reduce slippage between
the resilient cushioning member 120 and other parts of the mat 100
in contact with the resilient cushioning member 120. This non-slip
surface may also be referred to as an anti-slip surface.
[0038] FIG. 1D shows another cushioning member 120-1 that may be
employed as the resilient cushioning member 120. The resilient
cushioning member 120-1 of FIG. 1D includes a flexible sheet 125 of
material such as foam, polyurethane or other flexible material to
which multiple gel pads 130 are bonded or otherwise attached.
Resilient cushioning member 120-1 includes gel pads 130 arranged in
columns and rows as shown. The gel pads 130 depicted exhibit a
square geometry, but gel pads exhibiting other geometries such as
circular, rectangular, elliptical, and so forth may be employed as
well. For simplicity, FIG. 1D shows 2 columns and 4 rows of gel
pads 130. However, the ellipses in FIG. 1D indicate that the entire
surface of the flexible sheet 125 may be populated with gel pads to
provide a cushioning effect to the mat employing this resilient
cushioning member. In another embodiment, a substantially
continuous layer of gel may replace the gel pads 130.
[0039] FIG. 1E shows an alternative embodiment of a resilient
cushioning member 120-2 that may be used as resilient cushioning
member 120. Resilient cushioning member 120-2 is a sandwich that
includes a gel layer on a foam layer. In this embodiment, the gel
layer of resilient cushioning member 120-2 may face the bottom
surface 105B of wear element 105 when resilient cushioning member
120-2 is inserted in receiver 110. In this manner, resilient
cushioning member 120-2 exhibits multiple durometers.
[0040] FIG. 1F shows another alternative embodiment of a resilient
cushioning member 120-3 that may be used as resilient cushioning
member 120. Resilient cushioning member 120-3 is a sandwich that
includes a foam layer on a gel layer. In this embodiment, the foam
layer of resilient cushioning member 120-3 may face the bottom
surface 105B of wear element 105 when resilient cushioning member
120-3 is inserted in receiver 110. In this manner, resilient
cushioning member 120-3 exhibits multiple durometers.
[0041] FIG. 1G shows yet another alternative embodiment of a
resilient cushioning member 120-4 that may be used as resilient
cushioning member 120. Resilient cushioning member 120-4 is a
sandwich that includes a gel layer on a foam layer on a gel layer.
In this embodiment, one of the two gel layers of resilient
cushioning member 120-4 may face the bottom surface 1058 of wear
element 105 when resilient cushioning member 120-4 is inserted in
receiver 110. In this manner, resilient cushioning member 120-4
exhibits multiple durometers.
[0042] FIG. 1H shows still another alternative embodiment of a
resilient cushioning member 120-5 that may be used as resilient
cushioning member 120. Resilient cushioning member 120-5 is a
sandwich that includes a foam layer on a gel layer on a foam layer.
In this embodiment, one of the two foam layers of resilient
cushioning member 120-5 may face the bottom surface 1058 of wear
element 105 when resilient cushioning member 120-5 is inserted in
receiver 110. In this manner, resilient cushioning member 120-5
exhibits multiple durometers.
[0043] FIG. 1I shows the bottom 105B of the wear element 105 after
installation of the resilient cushioning member 120 through the
aperture 115 between receiver sections 110-1 and 110-2. The
resilient cushioning member 120 is shown in dotted lines to make it
visible even though it is captured inside the receiver 110 and
would otherwise not be clearly visible. In one embodiment, receiver
sections 110-1 and 110-2 may include respective external non-slip
surfaces to assist the mat 100 in remaining stationary when placed
on a surface for use. The portion of the wear element 105 not
occupied by the receiver 110 may also include such external
non-slip surfaces. In other words, the portion of the wear element
105 shown in FIG. 1D between the receiver 110 and the peripheral
edge of mat 100 may be outfitted with non-slip material. FIG. 1J
shows an alternative embodiment of anti-fatigue mat 100 wherein the
receiver 110 extends more closely to the peripheral edge of mat 100
than shown for the mat of FIG. 1I. In the embodiments illustrated
in FIGS. 1H and 1I above, there is no overlap between receiver
sections 110-1 and 110-2. Other embodiments are contemplated
wherein the receiver sections do overlap, as discussed in more
detail below.
[0044] FIG. 2A shows another embodiment of the disclosed
anti-fatigue mat as mat 200. Mat 200 of FIG. 2A includes elements
in common with mat 100 of FIG. 1A. Like numbers indicate like
elements when comparing mat 200 of FIG. 2A with mat 100 of FIG. 1A.
Mat 200 includes a receiver 210 with receiver sections 210-1 and
210-2. As discussed in more detail below, the resilient cushioning
member 120 will be installed in receiver 210 by moving resilient
cushioning member 120 through aperture 215 in empty receiver 210.
Receiver sections 210-1 and 210-2 include respective ends 210-1A
and 210-2A that overlap one another to form an overlap region 220.
Overlap region 220 is located adjacent aperture 215. Overlap region
220 may employ an overlap distance, OL, that exhibits a value of
approximately 0 cm to 10 cm depending on the particular
application. The overlap distance, OL, may exhibit values of
greater than approximately 10 cm such as 20 cm or more, depending
on the particular application. Generally, the overlap distance, OL,
should not be so large that it becomes excessively difficult to
insert resilient cushioning member 120 through aperture 215 and to
remove resilient cushioning member 120 from aperture 215.
[0045] In a manner similar to the anti-fatigue mat 100 of FIG. 1A,
the receiver 210 is situated on the bottom of the wear element 105
and may be integrally formed as a part of the wear element 105. The
receiver 210 may alternatively be attached to the remainder of the
wear element 105 by sewing adjacent the peripheral edge of the
receiver 210, or otherwise attaching receiver 210 to wear element
105. As discussed above, the receiver 210 of the wear element 105
includes an overlap region 220 where receiver section 210-1
overlaps above receiver section 210-2 adjacent the aperture 215
therebetween. The dashed line at the overlap region 220 indicates
that the end 210-2A of receiver section 210-2 facing receiver
section 210-1 passes below a portion of receiver section 210-1. In
this particular embodiment, overlap region 220 is formed by
situating receiver section end 210-1A above receiver section end
210-2A as shown. In an alternative embodiment, this relationship
may be inverted such that overlap region 220 is formed by situating
receiver section end 210-1A below receiver section 210-2A.
[0046] FIG. 2B shows the anti-fatigue mat 200 of FIG. 2A during the
process of installing or removing the resilient cushioning member
120 in the receiver 210 of the mat 200. Resilient cushioning member
120 includes opposed ends 120A and 120B as shown. To install the
resilient cushioning member 120, the user or other entity first
inserts the resilient cushioning member 120 into receiver section
210-2 by passing the resilient cushioning member end 120B through
the aperture 215 between the receiver sections 210-1 and 210-2. In
FIG. 2B, the partially installed resilient cushioning member 120 is
indicated by dotted lines to show that the resilient cushioning
member 120 is situated within receiver section 210-2. A portion of
the resilient cushioning member 120 including resilient cushioning
member end 120A extends outside of the receiver 210 in FIG. 2A
because the resilient cushioning member 120 is not yet completely
installed in the receiver 210.
[0047] Subsequently, the user or other entity places the remainder
of the resilient cushioning member 120 including resilient
cushioning member end 120A inside receiver section 210-1 such that
the fully assembled anti-fatigue mat 200 appears as illustrated in
FIG. 2C. The dotted line in FIG. 2C indicates the peripheral edge
of the resilient cushioning member 120 within the receiver 210. In
one embodiment, receiver sections 210-1 and 210-2 may include
respective non-slip surfaces to assist the mat 200 in remaining
stationary when placed on a surface for use. The portion of the
wear element 205 not occupied by the receiver 210 may also include
such non-slip surfaces.
[0048] To remove the resilient cushioning member 120 from the mat
200 for cleaning of the wear element 105 and/or cleaning of the
resilient cushioning member 120 itself or for other purposes, the
user reverses the installation procedure described above and
removes the resilient cushioning member 120 by extracting it
through the aperture 215. For example, as shown in FIG. 2D, the
user 227 may grasp receiver section 210-1 adjacent the aperture 215
and pull upward by hand to reveal the resilient cushioning member
120. The user 227 may extract the end 120A of the resilient
cushioning member 120 under receiver section 210-1 first and then
pull to remove the remaining portion of the resilient cushioning
member 120 under receiver section 210-2 through the aperture 215.
The receiver 210 of mat 200 is now again empty as shown above with
reference to FIG. 2A. With the resilient cushioning member 120 thus
removed, the wear element 105 is now easily washed, laundered or
otherwise cleaned.
[0049] FIG. 3A shows a cross sectional view of an anti-fatigue mat
300. Anti-fatigue mat 300 of FIG. 3A includes several elements that
are similar to like elements of anti-fatigue mat 100 of FIG. 1 and
anti-fatigue mat 200 of FIG. 2. Anti-fatigue mat 300 includes a
wear element 305 similar to wear element 105 of mat 100 and mat
200. Anti-fatigue mat 300 includes a receiver 310 with receiver
sections 310-1 and 310-2 arranged in overlapping fashion as shown
in FIG. 3A. Receiver 310 includes an overlap region (OL) 325. In
this particular embodiment, the portion of receiver section 310-1
that overlaps receiver section 310-2 is above receiver section
310-2 at overlap region 325. In another embodiment, the portion of
receiver section 310-1 that overlaps receiver section 310-2 may be
below receiver section 310-2 at overlap region 325.
[0050] Receiver 310 includes an aperture 315 at overlap region 325
through which a resilient cushioning member 320 may pass during
installation of resilient cushioning member 320 in mat 300 or
during removal of resilient cushioning member 320 from mat 300.
Resilient cushioning member 320 may be fabricated from the same
materials as resilient cushioning member 120 of mat 100 and mat
200. Resilient cushioning member 320 includes ramps at its
peripheral edges such as ramps 320A and 320B shown in FIG. 3A. In
this particular embodiment, resilient cushioning member 320
includes a substantially flat region 320C between ramps 320A and
320B. When the user installs resilient cushioning member 320 in
receiver 310 of mat 300 via aperture 315, wear element 305 conforms
to the geometry of the ramps of resilient cushioning member 320
such as ramps 320A and 320B as well as substantially flat region
320C. In this manner, resilient cushioning member 320 causes wear
element 305 to exhibit ramps such as ramp 305A, ramp 305B and a
substantially flat region 305C that correspond respectively to ramp
320A, ramp 320B and substantially flat region 320C of resilient
cushioning member 320. In other words, the geometry of wear element
305 follows the geometry of the resilient cushioning member 320
below wear element 305. As seen in FIG. 3C, one embodiment of
resilient cushioning member 320 includes ramps 320A, 320B, 320D and
320E. When the user or other entity installs this resilient
cushioning member 320 into anti-fatigue mat 300, this causes the
geometry of the wear element 305 of mat 300 to conform to the
geometry of the resilient cushioning member 320 therein, as shown
in FIG. 3E. As seen in FIG. 3E, the geometry of anti-fatigue mat
300 now includes wear element ramps 305A, 305B, 305D and 305E above
the now unseen resilient cushioning member ramps 320A, 320B, 32D
and 320E, respectively.
[0051] Returning to FIG. 3A, it is noted that the cross-section of
anti-fatigue mat 300 that FIG. 3A shows is a lengthwise
cross-section. It should be understood however that a cross-section
taken across the width of anti-fatigue mat 300 appears
substantially the same as the cross-section shown in FIG. 3A. Ramps
such as ramp 305A may thus appear on all four sides of anti-fatigue
mat 300. It should be understood that the cutaway portion of
anti-fatigue mat 300 on the right side of FIG. 3A indicates that
the length or width of anti-fatigue mat 300 may assume different
values rather than being limited to particular length and/or width
values.
[0052] The peripheral edges of wear element 305 are sewn or
otherwise connected to the adjacent peripheral edges of receiver
310 to hold receiver 310 to wear element 305. For example,
anti-fatigue mat 300 may include a serge 330 that surrounds the
peripheral edges of mat 300 to connect receiver 310 to wear element
305. Serge 330 provides a durable, attractive, high quality,
washable edge attachment for anti-fatigue mat 300.
[0053] FIG. 3B shows anti-fatigue mat 300 with the resilient
cushioning member 320 removed for cleaning or for use a as mat
without a cushioning member. With resilient cushioning member 320
removed, ramps 320A and 320B now lay flat and aligned with
substantially flat region 320C, as shown in FIG. 3B. Anti-fatigue
mat 300 is thus a "dual mode" mat that is useable in one mode where
resilient cushioning member 320 in installed in receiver 310, as
shown in FIG. 3A, and another mode where resilient cushioning
member 320 is removed from receiver 310, as shown in FIG. 3B. In
other words, by virtue of this "dual mode" feature, anti-fatigue
mat 300 is usable with or without resilient cushioning member 320
installed therein. Anti-fatigue mat 300 still functions with
receiver 310 empty, although mat 300 does not provide as much
resilience as when resilient cushioning member 320 is installed in
receiver 310.
[0054] As described above, anti-fatigue mat 300 includes a textile
wear element 305 and a non-slip receiver 310 that cooperate to
capture resilient cushioning member 320. In actual practice,
receiver 310 may include multiple receiver sections such as 310-1
and 310-2 that each exhibit non-slip properties. In this manner,
slippage or movement of anti-fatigue mat 300 on a floor or other
surface is prevented or decreased. In one embodiment, anti-fatigue
mat 300 exhibits a "dual mode" feature that cooperates with a
"dual-friction" feature to enable anti-fatigue mat 300 to be used
with or without resilient cushioning member 320. In one embodiment,
the "dual friction" feature refers to 1) the exterior surface of
receiver 310 exhibiting sufficient friction with respect to the
floor to reduce slippage between the mat and the floor, and 2) the
interior surface of wear element 305 exhibiting sufficient friction
with respect to the resilient cushioning member 320 to reduce
slippage therebetween. The "dual friction" feature is explained in
more detail below.
[0055] In one embodiment, resilient cushioning member 320 is a
molded-foam cushion as distinguished from the cut-foam that
resilient cushioning member 120 of FIG. 1C may employ. Molded-foam
resilient cushioning member 320 is shaped to include functional
lead-in ramps such as ramps 320A and 320B. This desirable lead-in
feature may reduce tripping while also serving to fill the portions
of receiver 310 adjacent the outer peripheral edges thereof, such
as those portions of the mat adjacent serge 330. Filling receiver
310 in this manner may provide anti-fatigue mat 300 with a smart
looking tight fit. In one embodiment, the angle of lead-in ramps
such as ramps 320A and 320B with respect to the horizontal axis is
within the range of approximately 18 degrees to approximately 20
degrees, although lead-in ramp angles outside of this range may
also be employed depending on the particular application. For
example, ramps exhibiting angles within the range of approximately
5 degrees to approximately 60 degrees may also perform acceptably
as long as the angle is not so small that the lead in ramp consumes
a substantial amount of the wear surface above or so large that a
user may trip. As seen in FIG. 3C, the resilient cushioning member
320 may include rounded corners 341, 342, 343 and 344 that make it
easier to insert the resilient cushioning member into the receiver
and to extract the resilient cushioning member from the
receiver.
[0056] As noted above, receiver 310 includes an opening or aperture
315 that receives resilient cushioning member 320 during
installation of resilient cushioning member 320 in receiver 310.
The receiver sections 310-1 and 310-2 overlap at overlap region
325. This overlap helps maintain tension on the bottom surface of
mat 300, i.e. the bottom exterior surface of mat 300 that receiver
310 forms. This tension helps mat 300 to lay flatter than would
otherwise be possible. More tension, i.e. increased overlap, allows
aperture 315 to close tightly so mat 300 does not slip on a floor.
While the mat will still function if there is no overlap, a mat
wherein the receiver sections overlap is desirable so that the
tensions of the interior and exterior surfaces of receiver 310
remain substantially even and consistent to enhance the aesthetics
and functionality of the mat.
[0057] As described above, in one embodiment, anti-fatigue mat 300
employs a "dual mode" feature and a "dual friction" feature that
cooperate to enhance mat performance. The "dual mode" feature
enables use of anti-fatigue mat 300 with or without resilient
cushioning member 320 installed therein. More particularly,
anti-fatigue mat 300 may operate in a first mode when resilient
cushioning member 320 is installed therein as shown in FIG. 3A, and
may alternatively operate in a second mode when the resilient
cushioning member 320 in not installed therein as shown in FIG.
3B.
[0058] Referring again to FIG. 3A, anti-fatigue mat 300 exhibits a
"dual friction" feature. In one aspect of the "dual friction"
feature, the exterior surface of receiver 310 is fabricated from
high-traction, i.e. high friction, non-slip material. The high
friction material of receiver 310 reduces mat slippage on a floor
on other surface, and provides part of the "dual-friction" feature
described above. In one embodiment, a surface exhibiting a static
coefficient of friction greater than approximately 1.0 is
considered to be "high friction". In one embodiment, the static
coefficient of friction should be sufficiently high that the
non-slip surface holds the anti-fatigue mat in place on the floor
or other surface where the anti-fatigue mat is used.
[0059] As another aspect of the "dual friction" feature, the
interior surface of wear element 305 may include a high friction
material that exhibits sufficient friction with respect to the
adjacent resilient cushioning member 320 to keep wear element 305
from gathering or bunching as a user drags their foot across wear
element 305. Such gathering or bunching in the wear element 305
would be unsightly and undesirable for the user aesthetically and
functionally when mat 300 operates in the first mode with the
resilient cushioning member 320 installed therein.
[0060] Moreover, when anti-fatigue mat 300 operates in the second
mode wherein no resilient cushioning member 320 is installed inside
mat 300 as shown in FIG. 3B, the high friction exhibited by the
interior surface of wear element 305 relative to the friction of
the interior surface of receiver 310 is sufficiently high to arrest
relative movement between the wear element 305 and receiver 310
which contact one another in the second mode. This configuration
enables the high friction exhibited by the interior surface of wear
element 305 to stabilize mat 300 both with and without resilient
cushioning member 120 installed in receiver 310. In this manner a
"dual mode", "dual friction" anti-fatigue mat 300 is provided. In a
preferred embodiment, the high friction interior surface of wear
element 305 cooperates with a low friction interior surface of
receiver 310 to facilitate installation and removal of resilient
cushioning member 320 from receiver 310.
[0061] In an alternative embodiment, the top surface of resilient
cushioning member 320 may exhibit high friction to reduce movement
of wear element 305 with respect to the top surface of resilient
cushioning member 320. In that embodiment, the interior surface of
wear element 305 need not exhibit high friction. In another
embodiment, both the interior surface of wear element 305 and the
top surface of resilient cushioning member may exhibit high
friction.
[0062] In one embodiment, the interior surface of the receiver 310,
i.e. the surface of receiver 310 that faces wear element 305,
exhibits low friction relative to resilient cushioning member 320
to facilitate moving resilient cushioning member 320 into receiver
310 and removing resilient cushioning member 320 from receiver 310.
For example, a lower-friction fabric backing may be applied to the
interior surface of receiver 310. By lower-friction is meant a
friction value that is less than the much higher friction value
that the interior surface of wear element 305 exhibits. In one
embodiment, the friction exhibited by the interior surface of
receiver 310 is sufficiently low to enable resilient cushioning
member 320 to slide over the interior surface of receiver 310 when
the resilient cushioning member 320 is installed or removed. In one
embodiment, the resilient cushioning member 320 and the receiver
310 are substantially parallel to the flat region 320C of wear
member 305.
[0063] FIG. 3C is a top perspective view of molded-foam resilient
cushioning member 320 that may be used in anti-fatigue mat 300.
Resilient cushioning member 320 includes lead-in ramps 320A and
320B, and further includes lead-in ramps 320D and 320E that are not
visible in the views of the other drawings. Resilient cushioning
member 320 includes rounded corners 341, 342, 343 and 344 that
facilitate insertion and removal of resilient cushioning member 320
from mat 300.
[0064] FIG. 3D is a bottom plan view of anti-fatigue mat 300 that
shows receiver 310 including receiver section 310-1 and receiver
section 310-2 with aperture 315 therebetween. This view also shows
the serge 330 as surrounding the peripheral edge of mat 300.
[0065] FIG. 3E shows a perspective view of a fully assembled
anti-fatigue mat 300 with a resilient cushioning member 320
installed therein. Lead-in ramps 305A, 305B, 305C and 305D are
visible in this view. Serge 330 is also visible in this view.
[0066] FIG. 4A shows a perspective view of an alternative
embodiment of the anti-fatigue mat as anti-fatigue mat 300'. FIG.
4B shows a plan view of anti-fatigue mat 300'. As the lengthwise
dimension of the anti-fatigue mat increases, it may become more
difficult to install the resilient cushioning member through an
aperture in the receiver. Anti-fatigue mat 300' of FIG. 4A is
similar to anti-fatigue mat 300 of FIGS. 3A-3E, except that mat
300' may be longer than mat 300, and mat 300' employs a receiver
405 that exhibits a different configuration than receiver 310 of
mat 300.
[0067] More particularly, anti-fatigue mat 300' includes a receiver
405 that includes receiver sections 405-1, 405-2 and 405-3.
Anti-fatigue mat 300' includes a primary opening, i.e. a primary
aperture 415, between receiver section 405-2 and receiver section
405-3. The user may insert the resilient cushioning member (not
shown) into primary aperture 415 between receiver section 405-2 and
receiver section 405-3 to install the resilient cushioning member
in anti-fatigue mat 300'. Anti-fatigue mat 300' also includes a
secondary opening, i.e. a secondary aperture 425, between receiver
section 405-1 and receiver section 405-2. To install the resilient
cushioning member, the user may push the resilient cushioning
member into aperture 415 and pull the resilient cushioning member
further into receiver 405 by accessing receiver 405 through
aperture 425. To remove the resilient cushioning member from
receiver 405 of anti-fatigue mat 300', the user may reverse the
above-described procedure. In one embodiment, primary aperture 415
and secondary aperture 425 extend substantially the entire distance
between opposed edges 450 and 455 in the widthwise dimension of
anti-fatigue mat 300'.
[0068] Anti-fatigue mat 300' includes overlap regions 435 and 445
that are formed in substantially the same manner as overlap region
325 of anti-fatigue mat 300. Overlap region 435 is formed at
aperture 415. Receiver section 405-3 overlaps receiver section
405-2 at aperture 415 to form overlap region 345. Overlap region
445 is formed at aperture 425. Receiver section 405-2 overlaps
receiver section 405-1 at aperture 425 to form overlap region 445.
Overlap regions 435 and 445 may perform the same functions as
overlap region 325 of anti-fatigue mat 300, such as holding the mat
in tension. Although not visible in FIG. 4A or 4B, a resilient
cushioning member similar to resilient cushioning member 320 is
installed in receiver 405 of anti-fatigue mat 300'.
[0069] FIG. 5A shows an anti-fatigue mat 300'' that is similar to
anti-fatigue mat 300' of FIG. 4A, except that anti-fatigue mat
300'' includes one or more access openings, such as openings 510-1
and 510-2 for example. FIG. 5B shows a plan view of anti-fatigue
mat 300'' with resilient cushioning member 320 visible in openings
510-1 and 510-2. In one embodiment, openings 510-1 and 510-2
exhibit a different geometry than apertures 415 and 425. For
example, apertures 415 and 425 appear as a one-dimensional slit
extending between the opposed edges 450 and 455 of mat 300'',
whereas openings 510-1 and 510-2 exhibit a 2 dimensional geometry
that extends across a portion of, but not the entirety of, the
widthwise dimension between opposed edges 450 and 455. More
particularly, openings 510-1 and 510-2 may exhibit a 2-dimensional
geometry such as rectangular, as shown, square, circular,
elliptical as well as other 2-dimensional geometries that allow the
user's hand to access the interior of receiver 505. Apertures 415,
425 and openings 510-1, 510-2 may all facilitate the user's access
to the interior of receiver 505 to enable the user to position
resilient cushioning member 320 within receiver 505 such that the
four corners of resilient cushioning member 320 extend fully to the
four corners of mat 300'' interior to receiver 505. In one
embodiment, opening 510-1 is centered between opposed edges 450 and
455, so as to exhibit a width approximately one third of the
distance between opposed edges 450 and 455. In one embodiment,
opening 510-1 may be larger than illustrated, but should not be so
large as to negatively impact the structural integrity of
anti-fatigue mat 300''. In another embodiment, mat 300'' may not
include aperture 425. In such an embodiment, the user may access
the resilient cushioning member 320 inside mat 300'' via opening
510-2 instead of aperture 425. In yet another embodiment, the mat
300'' may not include opening 510-2 and aperture 425. In such an
embodiment, the user may access the resilient cushioning member 320
via opening 510-1 instead of opening 510-2 and aperture 245.
[0070] Anti-fatigue mats that are very long, such as those
approximately 48 inches or longer may include multiple resilient
cushioning member sections that connect together to form the entire
resilient cushioning member. FIG. 6A shows such a resilient
cushioning member 600 that includes resilient cushioning member
sections 601, 602 and 603. Resilient cushioning member sections
601, 602 and 603 connect together in end-to-end fashion to form the
long resilient cushioning member 600 that FIG. 6A depicts.
Resilient cushioning member section 601 includes opposed ends 601A
and 601B. Resilient cushioning member section 602 includes opposed
ends 602A and 602B. Resilient cushioning member section 603
includes opposed ends 603A and 603B.
[0071] Each resilient cushioning member section, such as section
601, includes an interlocking connector that connects that section
to a corresponding mating interlocking connector of an adjacent
section, such as section 602, to hold each section to the other
section. One type of connector that is usable as such an
interlocking connector is a puzzle-piece connector, as shown in
FIG. 6A. For example, resilient cushioning member section 601
includes a puzzle-piece connector 605 that mates with a
complementary puzzle-piece connector 610 of adjacent resilient
cushioning member section 602. Resilient cushioning member section
602 includes another puzzle-piece connector 615 that mates with a
complementary puzzle-piece connector 620 of adjacent resilient
cushioning member section 603. It will be appreciated that even
longer resilient cushioning members may be formed by adding more
resilient cushioning member sections with interlocking
connectors.
[0072] Although not specifically illustrated in FIG. 6A, resilient
cushioning member 600 may include lead-in ramps on its four sides
in the same manner that resilient cushioning member 320 of FIG. 3C
includes lead-in ramps. Die-cutting foam material is one way to
form resilient cushioning member 600 with interlocking
connectors.
[0073] FIG. 6B shows an assembled, long anti-fatigue mat 650 with
resilient cushioning member 600 installed therein. Before
installing resilient cushioning member 600 in receiver 660 of
anti-fatigue mat 650, the user may assemble resilient cushioning
member 600 as shown in FIG. 6A. FIG. 6B shows a plan view of the
bottom of anti-fatigue mat 600 that includes a receiver 660 having
receiver sections 661, 662 and 663. Receiver 660 includes an
opening 665 that is positioned to make puzzle-piece connectors 605
and 610 accessible to the user during and after assembly of
anti-fatigue mat 650. Receiver 660 may also include an opening 670
that is positioned to make puzzle-piece connectors 605 and 610
accessible to the user during and after assembly of anti-fatigue
mat 650. Openings 665 and 670 may exhibit an oval, elliptical,
scalloped or other geometry that allows receiver section 661 to
overlap receiver section 662 at opposed edges 650A and 650B, as
shown in the close-up view of the overlap that FIG. 6C provides. As
seen in FIG. 6C, receiver section 661 overlaps receiver section 662
by an overlap distance value, OL, adjacent edge 650A. In one
embodiment, the overlap value OL may be with the range of
approximately 10 cm to approximately 20 cm. There is a similar
overlap between receiver section 661 and receiver section 662 at
the opposite edge 650B of mat 650, as shown in FIG. 6B. In a manner
similar to that described above, receiver section 662 overlaps
receiver section 663 adjacent opposed edges 650A and 650B at
opening 670. The overlap provided in the regions designated, OL,
above helps to maintain tension on mat 650 which aids in
maintaining the tightness of the wear element (not shown) of the
mat 650. The wear element of mat 650 is not visible in FIG. 6B
because the wear element is on the side of the mat opposite that
which FIG. 6B depicts. The wear element that mat 650 employs is
similar to the wear element 305 shown in FIG. 3A except that the
wear element is appropriately longer to accommodate the increased
length of mat 650.
[0074] In one embodiment, resilient cushioning member 320 need not
be fully assembled prior to installation in receiver 660 of mat
650. Referring again to FIG. 6B, the user may install resilient
cushioning member section 601 in opening 665 and resilient
cushioning member section 602 in either opening 665 or 670. After
placing resilient cushioning member sections 601 and 602 inside of
receiver 660, the user positions resilient cushioning member
sections 601 and 602 adjacent one another at opening 665 such that
resilient cushioning member section 601 connects to resilient
cushioning member section 602, as shown. The user may insert
resilient cushioning member section 603 through opening 670 and
further position resilient cushioning member section 603 to connect
to resilient cushioning member section 602, as shown. To
disassemble anti-fatigue mat 605, the above-described procedure is
reversed.
[0075] In the embodiment described above, if anti-fatigue mat 650
is folded, such as during shipping or storage, a natural bend point
occurs at open regions 665 and 670 where the resilient cushioning
member sections connect, as shown. This allows the assembled mat
650 to bend at openings 665 and 670 where adjacent resilient
cushioning member sections connect together.
[0076] FIG. 7A shows another embodiment of the resilient cushioning
member 700 that the disclosed anti-fatigue mat may employ.
Resilient cushioning member 700 is a molded foam cushioning member
in one embodiment. Resilient cushioning member 700 includes
resilient cushioning member sections 701 and 702. Resilient
cushioning member sections 701 and 702 connect together in
end-to-end fashion to form the long resilient cushioning member 700
that FIG. 7A depicts. To facilitate connecting resilient cushioning
member section 701 to resilient cushioning member section 702,
resilient cushioning member 701 includes an interlocking connector
705 and resilient cushioning member 702 includes a corresponding
interlocking connector 710. Puzzle-piece connectors may be employed
as interlocking connectors 705 and 710 as shown in FIG. 7A and more
clearly in FIG. 7B.
[0077] FIG. 7B shows a close-up view of the portion of resilient
cushioning member 700 where resilient cushioning members sections
701 and 702 connect together. The view of FIG. 7B is rotated 180
degrees as compared with the view of FIG. 7A. As shown in FIG. 7B,
resilient cushioning member section 701 includes an interlocking
connector 705 that connects section 701 to an interlocking
connector 710 of adjacent resilient cushioning member section 702
to hold each section to the other section. One type of connector
that is usable as such an interlocking connector is a puzzle-piece
connector as shown in FIG. 7B. For example, in this embodiment
where a puzzle-piece connector is used as the interlocking
connector, resilient cushioning member section 701 includes a
puzzle-piece connector 705 that mates with a complementary
puzzle-piece connector 710 of adjacent resilient cushioning member
section 702. In one embodiment, one of the two puzzle-piece
connectors may include a ledge on which individual connective
elements of that connector sit. For example, puzzle-piece connector
705 of resilient cushioning member 701 includes a ledge 715 on
which individual puzzle piece connective elements, such as element
720, are situated.
[0078] To assemble resilient cushioning member 700, a user presses
puzzle-piece connector 710 into the puzzle piece connector 705 such
that one mates with the other to connect resilient cushioning
member section 702 to resilient cushioning member section 701. It
will be appreciated that even longer resilient cushioning members
may be formed by adding more resilient cushioning member sections
with interlocking connectors in a manner similar to that of
resilient cushioning member 600 of FIG. 6A. When fully assembled,
resilient cushioning member 700 appears similar to resilient
cushioning member 320 of FIG. 3C, except for a line visible where
puzzle piece connectors 705 and 710 connect together. Referring
again to FIG. 7A, resilient cushioning member includes 700
respective lead-in ramps similar to the lead-in ramps of FIG. 3C.
For example, lead-in ramps 700A, 700B and 700C are visible in
resilient cushioning member 700 of FIG. 7A. Resilient cushioning
member 700 may be assembled either before or after connecting
resilient cushioning member sections 701 and 702 together.
Receivers similar to receiver 405 of FIG. 4A, or receiver 660 of
FIG. 6B, may be used together with resilient cushioning member 700
to form an anti-fatigue mat.
[0079] The disclosed anti-fatigue mat may provide substantially
increased cushioning ability in comparison with the minimal
cushioning that a rug or carpet would provide alone. In one
embodiment, the anti-fatigue mat provides an amply cushioned
anti-fatigue capability and a nicely styled wear surface that gives
a natural feeling when the user stands on the mat. Moreover, in one
embodiment, when the resilient cushioning member is removed from
the mat, the wear surface may be machine washable or more easily
cleanable than otherwise possible.
[0080] The following discusses attributes and features of different
embodiments of the disclosed anti-fatigue mat. The resilient
cushioning member may be sufficiently inset from, or sufficiently
spaced-apart from, the peripheral edges of the wear element to form
a lead-in ramp that assists in reducing the likelihood of tripping
on the edge of the mat. The receiver sections may be fabricated
from non-slip materials to hold the mat in position on a floor or
other surface. The receiver sections may be fabricated from a
material similar to rug material, for example cotton, so that wear
element and receiver shrink at the same rate when the mat is washed
after removal of the resilient cushioning member. In an alternative
embodiment, sections of the cushioning element may be exposed to
the floor through additional openings in the receiver to provide a
non-slip surface.
[0081] A number of different ways are contemplated for holding the
resilient cushioning member to the wear element, wherein the wear
element may be fabricated from rug-like material, such as textiles.
In one embodiment, hook and loop fasteners may hold the resilient
cushioning member to the wear element. Mechanical fasteners may
removably hold the resilient cushioning member and the wear element
together. Two short pockets may be coupled to the respective
opposed ends of the wear element. In that embodiment, the resilient
cushioning member bends to thread into each pocket. In one
embodiment, the receiver may include a zipper at the aperture to
zip a first receiver section to a second receiver section, thus
holding and closing the resilient cushioning member within the
receiver. In an alternative embodiment, the aperture and the zipper
may be moved to other locations, such as along one long edge of the
receiver. In another embodiment, safety pins molded into the
resilient cushioning member may attach to the wear element.
Alternatively, button-hole fasteners may fit through slots in the
resilient cushioning member and may even provide another non-slip
element.
[0082] In yet another embodiment, weak adhesive on the top side of
the resilient cushioning member may removably hold the resilient
cushioning member to the wear element. Alternatively, the resilient
cushioning member and the wear element may be outfitted with
magnetic material to removably hold one to the other. In another
embodiment, the corners of the wear element may be outfitted with
fabric corners to hold the resilient cushioning member in place on
the wear element in a manner like a picture in a photo album.
Alternatively, triangular flaps may fold over each edge of the
resilient cushioning member and employ either a button-hole
mechanism or a snap tie mechanism in the middle of the resilient
cushioning member to hold the resilient cushioning member to the
wear element. The resilient cushioning member may snap onto the
wear element. In yet another embodiment, the receiver may snap onto
the wear element. The receiver provides a cavity for holding the
resilient cushioning member. In another embodiment, a hinge is
formed by loops on the wear element and cushioning element, wherein
a rod is passed through the loops of the wear element and the loops
of the cushioning element to hold one to the other. In yet another
embodiment, elastic loops on the wear element may stretch around
the resilient cushioning member to hold one to the other. In still
another embodiment, the resilient cushioning member is permanently
attached to the wear element without a receiver by an adhesive
coupling, bonding or other permanent attachment therebetween.
[0083] In yet another embodiment, the resilient cushioning member
is placed in a pillow case-like member, wherein the pillow
case-like member is attached to the wear element rather then being
sewn. In another embodiment, gel or smooth plastic circles situated
on the wear element connect with corresponding gel or smooth
plastic circles situated on the cushioning element to create a
static-cling connection or coupling. In another embodiment, metal
hooks are molded into the resilient cushioning member to connect
the resilient cushioning member to the wear element in a
drapery-hook type arrangement. In still another embodiment, the
wear element is outfitted with an elastic loop that goes through
the wear element through a slit in the resilient cushioning member.
A pin or rod extends through the elastic loop to hold the resilient
cushioning member to the wear element. The rod or pin is pulled
with force into the resilient cushioning member so that it does not
scratch the floor or other surface. In yet another embodiment,
removable staples pierce the wear element and attach to molded-in
sockets in the resilient cushioning member to hold the resilient
cushioning member to the wear element. In still another embodiment,
clips attached to the wear element and/or resilient cushioning
member hold each to the other.
[0084] in summary, in one embodiment, the disclosed anti-fatigue
mat includes a "dual mode" feature and a "dual friction" feature
that cooperate to provide a desirable, flexible anti-fatigue mat.
The dual mode feature enables the mat to operate in a first mode
with the resilient cushioning member installed inside the receiver.
The mat also operates in a second mode in which the receiver of the
mat does not contain the resilient cushioning member. The resilient
cushioning member of the mat is removable and the mat will still
function although with less cushioning effect in the second mode
than with the resilient cushioning member inside the receiver in
the first mode.
[0085] The disclosed anti-fatigue mat also includes a "dual
friction" feature. In one aspect of the dual friction feature, the
interior surface of the wear element exhibits high friction with
respect to the upper surface of the resilient cushioning member. In
this manner, slippage between the wear element and the cushioning
member and bunching of the wear element are reduced. This occurs in
the first mode wherein the resilient cushioning member is installed
in the receiver of the mat. In another aspect of the dual friction
feature, when the resilient cushioning member is removed from the
mat such as during the second mode, the high friction interior
surface of the wear element contacts the interior surface of the
receiver to reduce motion between the wear element and the
receiver.
[0086] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
[0087] The corresponding structures, materials, acts, and
equivalents of all means or step plus function elements in the
claims below are intended to include any structure, material, or
act for performing the function in combination with other claimed
elements as specifically claimed. The description of the present
invention has been presented for purposes of illustration and
description, but is not intended to be exhaustive or limited to the
invention in the form disclosed. Many modifications and variations
will be apparent to those of ordinary skill in the art without
departing from the scope and spirit of the invention. The
embodiment was chosen and described in order to best explain the
principles of the invention and the practical application, and to
enable others of ordinary skill in the art to understand the
invention for various embodiments with various modifications as are
suited to the particular use contemplated.
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